7 Keys to Implementing Mistake Proofing Systems
November 1, 2004
Mistake proofing is a powerful
tool for creating more stable processes by reducing defects.
Processes with high defect rates are very problematic for the
lean producer: such processes are not conducive to a lean value
stream because they require overproduction to ensure that demand is
met. This article will teach
you how to implement an effective mistake proofing system.
This article talks about seven
keys to implementing an effective
mistake proofing system:
Key #1:
Create a team and always include those people that work on process
in question. Organizations
still have the tendency to turn to “technical experts” working in
isolation to implement poka-yoke systems.
Involving operators in a team setting will dramatically
increase the likelihood of success.
A kaizen blitz event is one very effective team activity for
implementing mistake proofing.
Key #2: Use
Value Stream Mapping to determine where process stability must
improve. (If you are not
familiar with value stream mapping, go back and read our series of
articles on the subject.)
This will allow you to focus on areas that will impact continuous
flow.
Key #3: Use process mapping within the area selected. If you are implementing mistake proofing as a part of a kaizen blitz event, then this step should be done as a matter of course. However, if you are not using this methodology, you still need to map the current state process in detail. This will clearly identify each process step.
Key #4:
Use a simple problem
solving methodology like a fishbone diagram to determine root causes
of problems within the process.
This will identify those specific steps in the process that
need mistake proofing.
Key #5: Use
the simplest technology that will work when implementing a
poka-yoke. Many times,
low-tech solutions like guide pins and limit switches will work
effectively. However, there
are times when more complicated systems are necessary.
Key #6: Use
control systems instead of warning systems wherever practical
because control systems are not operator-dependent.
(Control systems stop equipment when an irregularity happens,
while a warning system signals the operator to take action).
Key #7: Have
a standard form for every “Poka-Yoke” that indicates the:
·
Problem being addressed
·
Emergency
alarm that will sound
·
Action to be
taken in an emergency
·
Method and
frequency of confirming it is operating correctly
·
Method to perform a quality check
in case of breakdown
Mistake proofing systems are critical to
the success of a lean organization simply because process stability
is so critical. Using the
above seven keys will improve the likelihood of implementing a
successful mistake proofing program.
Click here to subscribe to our free e-newsletter Learning to Lean and receive three articles like this one each month.
About the Author
Darren Dolcemascolo is an internationally recognized lecturer, author, and consultant. As Sr. Partner and co-founder of EMS Consulting Group, he specializes in productivity and quality improvement through lean manufacturing. Mr. Dolcemascolo has written the book Improving the Extended Value Stream: Lean for the Entire Supply Chain, published by Productivity Press in 2006. He has also been published in several manufacturing publications and has spoken at such venues as the Lean Management Solutions Conference, Outsourcing World Summit, Biophex, APICS, and ASQ. He has a BS in Industrial Engineering from Columbia University and an MBA with Graduate Honors from San Diego State University.
EMS Consulting Group helps companies implement lean strategies through lean training and lean consulting services. To learn more, read our lean manufacturing case studies or lean manufacturing articles.